LED automotive tail lamp set

ABSTRACT

The present invention relates to LED lamps suitable for forming automotive lighting systems, made of high power lambertian LEDs and a TIR collimator lens. In the present invention, a novel TIR collimator lens is developed to collect the light emitted from the LED source and through a pillow lens array; redistribution occurs to form a light pattern meeting ECE requirements.

BACKGROUND

Traditional tail lamps use halogen filament light sources. With the rapid and steady increase of the LED flux during the last decade, LEDs are not widely used in automotive lighting systems for their durability, reliability, longer life, quicker response time, lower power consumption, compact package size, availability of red, white, and amber colors naturally, and more design flexibility offering different styling options. However, there are challenges with respect to the use of LEDs due to their relatively low flux output.

In the current market, LED tail lamps almost do not form a light pattern, rather several LEDs are assembled together. This does not allow for maximum efficiency.

It is an object of the present invention to overcome the disadvantages and problems in the prior art.

DESCRIPTION

The present invention relates to LED lamps suitable for forming automotive lighting systems, made of high power lambertian LEDs and a TIR collimator lens. In the present invention, a novel TIR collimator lens is developed to collect the light emitted from the LED source and through a pillow lens array; redistribution occurs to form a light pattern meeting ECE regulations.

These and other features, aspects, and advantages of the apparatus and methods of the present invention will become better understood from the following description, appended claims, and accompanying drawings, as discussed below.

The following description of certain exemplary embodiment(s) is merely exemplary in nature and is in no way intended to limit the invention, its application, or uses. As used herein, a “lambertian LED” refers to a light emitting diode that obeys Lambert's cosine law, defined as the radiant intensity directly proportional to the cosine of an angle Θ between the observer's line of sight and the surface normal.

Now, to FIGS. 1-14,

FIG. 1 is an embodiment of the present lamp unit 101 to be used in an automotive lighting system, having an LED housing unit 102 and a total internal reflection (TIR) lens 104 with a front 103 and a back 105. (a) is a side view of the unit 101. The TIR lens unit is constituted by an outside TIR surface and a control aspheric collimating lens. The design of the TIR lens can be defined as a total internal reflection lens having two connected mirror image sides, whereby each side has a convex dome attached to an upward sloping face leveling off to form a lip, whereby the bottom side of the lip is attached to a downward sloping face attached to a vertical face, and then to a horizontal convex face. A LED housing unit 102 is positioned below the lens. Through the design of the lamp unit, light from an LED within the LED housing unit 102 is forwarded to a distance “F” 106. Hence, the light from the LED transmits through the surfaces “A” 105 and “B” 103 and are collimated.

As shown in (b), the lamp 101 is hexagon in shape.

FIG. 2 is a three dimensional view of the present lamp, during use, i.e., light exiting the lamp unit. (a) is a side view and (b) is a perspective view.

FIG. 3 is an embodiment of a lamp system of the present system, made of 3 lamps 301 of the present invention. This embodiment is useful in an automotive lighting systems, specifically backup lights and turn signal lights.

FIG. 4 shows light from a lamp system having 3 lamps, of the present invention, sent out to a distance.

FIG. 5 is another embodiment of a lamp system to be used in an automobile lighting system, in accordance with the present invention. In this embodiment, 7 lamps are utilized in the lamp system. This embodiment is suitable for brake light and park light.

FIGS. 6( a-c) exhibits a brake light or park light lamp system of the present invention, providing light for a distance.

Lenses are placed over the lamp systems, thereby affecting the reflectance and scattering of the light sent from the lamp systems. Lenses can have a variety of designs, for example lenses having refractive and/or scattering pattern. Designs, such as those described in U.S. Pat. No. 6,818,276, incorporated herein by reference, are suitable for use herein.

Scattering of the light delivered from the present lamp system can be described as follows:

${\sin \; \alpha_{1}} = {\frac{1}{n}\sin \; \alpha}$ β = α₁ + α₂, α₂ = β − α₁ n sin (β − α₁) = sin  β n(sin  β cos  α₁ − cos  β sin  α₁) = sin  β ${\cos \; \alpha_{1}} = {\frac{1}{n}\sqrt{n^{2} - {\sin^{2}\alpha}}}$ ${n\left( {{\sin \; {\beta \cdot \frac{1}{n}}\sqrt{n^{2} - {\sin^{2}\alpha}}} - {\cos \; {\beta \cdot \frac{1}{n}}\sin \; \alpha}} \right)} = {\sin \; \beta}$ ${\sqrt{n^{2} - {\sin^{2}\alpha}} - {{ctg}\; {\beta \cdot \sin}\; \alpha}} = 1$ ${{ctg}\; \beta} = {\frac{\sqrt{n^{2} - {\sin^{2}\alpha}} - 1}{\sin \; \alpha} = {2\frac{\sqrt{R^{2} - \left( \frac{L}{2} \right)^{2}}}{L}}}$ $R = \frac{L \cdot \sqrt{n^{2} - {2\sqrt{n^{2} - {\sin^{2}\alpha}}} + 1}}{2\; \sin \; \alpha}$

FIG. 7 sketches a scattering pattern according to the present invention.

Refractive light from the present lamp can be described as follows:

n sin  α₂ = sin  α α₁ = β − α₂, sin  β = n sin (β − α₂), sin  β = n(sin  βcos α₂ − cos  β sin  α₂) n cos  α₂ − nctg β sin  α₂ = 1 ${{ctg}\; \beta} = \frac{{\cos \; \alpha_{2}} - \frac{1}{n}}{\sin \; \alpha_{2}}$ ${{ctg}\; \beta} = {\frac{\sqrt{1 - {\frac{1}{n^{2}}\sin^{2}\alpha}} - \frac{1}{n}}{\frac{1}{n}\sin \; \alpha} = {\frac{\sqrt{n^{2} - {\sin^{2}\alpha}} - 1}{\sin \; \alpha} = \frac{L}{H}}}$ $H = \frac{L\; \sin \; \alpha}{\sqrt{n^{2} - {\sin^{2}\alpha}} - 1}$

FIG. 8 sketches a refractive pattern according to the present invention.

FIG. 9 is an embodiment of an automotive lighting system 900 possessing the present lamp system. The lighting system 900 includes a brake light 901, park light 903, turn signal light 905, and backup light 907.

FIG. 10 is a schematic breakdown of an automotive lighting system 1000, whereby the lamp systems 1001 fit within compartments 1002 of the lighting system housing 1003.

FIGS. 11( a+b) shows a lamp system 1100 of the present invention, including several LED lamps 1103 made in accordance with the present invention and a lens 1101 for scattering, reflecting, or scattering and reflecting the LED light. In this particular embodiment, 7 LED lamps are utilized.

3 or 7 lamp units are not the unique choice for the automobile lamp tail; 3 or 7 lamp units are just one of our many combinations. 4, 5 or 8, 9 lamp units can be accomplished to fit the requirement of the automobile lamp tail set.

EXAMPLE

Testing was performed on several of the lamp systems within an automotive lighting systems.

FIGS. 12( a+c) exhibits the testing of a brake and parking light of an automobile, made from a lamp systems and lamps of the present invention. Table 1 shows the results of the testing and how they match up against ECE requirements.

TABLE 1 Requirement (ECE) Luminous intensity Testing point Min Max (Unit: cd) Pass or Negative 10U/D  5L 8 100 13.9 Pass V — 14.6 Pass  5R 8 13.4 Pass  5U/D 20L 4 100 8.4 Pass 10L 8 30.0 Pass V 28 39.3 Pass 10R 8 29.7 Pass 20R 4 8.5 Pass H 10L 14 100 33.8 Pass  5L 36 40.1 Pass V 40 45.2 Pass  5R 36 41.5 Pass 10R 14 33.3 Pass

FIG. 13 exhibits the testing of a backup light of an automobile, made from a lamp system and lamps of the present invention. Table 2 shows the results of the testing and how they match up against ECE requirements.

TABLE 2 Requirement (ECE) Luminous intensity Testing point Min Max (Unit: cd) Pass or Negative 10U/D  5L 10 350 22.8 Pass V — 24.8 Pass  5R 10 23.0 Pass  5U/D 20L  5 350 13.5 Pass 10L 10 36.3 Pass V 35 43.9 Pass 10R 10 38.0 Pass 20R  5 13.8 Pass

FIG. 14 exhibits the testing of a turn signal light of an automobile, made from a lamp system and lamps of the present invention. Table 3 shows the results of the testign and how they match up against ECE requirements.

TABLE 3 Requirement (ECE) Luminous intensity Testing point Min Max (Unit: cd) Pass or Negative 10U 10L 10 300 15.4 Pass V 15 23.0 Pass 10R 10 13.9 Pass  5U 45L 15 300 26.7 Pass 10L 20 60.1 Pass V 25 83.5 Pass 10R 20 61.5 Pass 45R 15 20.6 Pass H and 5D 45L 15 300 24.5 Pass 30L 25 52.6 Pass 10L 50 86.4 Pass V 80 90.5 Pass 10R 50 85.7 Pass 30R 25 50.9 Pass 45R 15 25.1 Pass H-H down 600 — Pass

Having described embodiments of the present system with reference to the accompanying drawings, it is to be understood that the present system is not limited to the precise embodiments, and that various changes and modifications may be effected therein by one having ordinary skill in the art without departing from the scope or spirit as defined in the appended claims.

In interpreting the appended claims, it should be understood that:

a) the word “comprising” does not exclude the presence of other elements or acts than those listed in the given claim;

b) the word “a” or “an” preceding an element does not exclude the presence of a plurality of such elements;

c) any reference signs in the claims do not limit their scope;

d) any of the disclosed devices or portions thereof may be combined together or separated into further portions unless specifically stated otherwise; and

e) no specific sequence of acts or steps is intended to be required unless specifically indicated. 

1. A lamp unit for an automotive tail lamp set, comprising: a total internal reflection lens, having two connected mirror image sides, whereby each side has a convex dome attached to an upward sloping face leveling off to form a lip, whereby the bottom side of said lip is attached to a downward sloping face attached to a vertical face, then to a horizontal, convex face; and an LED housing unit having an LED; wherein said total internal reflection lens is hexagonal and said LED housing unit is positioned beneath said total internal reflection lens.
 2. The lamp unit of claim 1, wherein said LED is a lambertian LED colored white, red, yellow, or orange.
 3. An automobile lamp tail set, comprising: between 3 and 7 lamp units, wherein each lamp unit is made of a total internal reflection lens having two connected mirror image sides, whereby each side has a convex dome attached to an upward sloping face leveling off to form a lip, whereby the bottom side of said lip is attached to a downward sloping face attached to a vertical face, then to a horizontal, convex face; and an LED housing unit having a lambertian LED.
 4. The automobile lamp tail set of claim 3, wherein said tail set includes one or more selected from the group consisting of brake light, a park light, a turn signal light, and a backup light.
 5. The automobile lamp tail set of claim 3, wherein said lens can be made of Polycarbonate (PC), PMMA, and some other optical grade plastic materials. 